VA Lean Kaikaku

Non competitive organization Cross-Learning of TPS Implementation.

Thank you Mega Label for hosting for the TPS cross-learning session.

🙏🏻 Special thanks to for the generous and unreserved sharing of the TPS implementation journey. ❤️

Thank you for exchange many many notes with solid horizon team despite your busy schedule. They express much appreciation. ❤️

Thank you for leading a team that has open up the 3rd eye for Genba contributing to the cross learning session. 👍👍💪💪
Let’s host Mega Label too in near future after completing the upgrading work for the exchange.

Factory Layout and Work Flow

A factory layout with good flow, designed with simplifying operator’s work in mind will help contribute to tremendous amount of lead-time reduction achieving the goals of TPs which is “Highest Quality, Lowest Cost, Shortest Lead-Time”.

Inventory and warehouse management challenges.

Helping customer to understand the stock level by applying the “Z” chart analysis.

1. What is the daily maximum consumption (n)?
2. What is the lead time supplier required to re-stock?
3. Establishing safety stock buffer level (n+x)?
4. Linking with delivery planned schedules!

Applying the smaller batch size will help to free up inventory holding cost and increase cashflow in hand.

It was a great opportunity to meet Tan Sri Dato Sri Ben Yeoh, the CEO of Bermaz Auto.

Learning about his journey of entrepreneurship and the appetite for risk couple with his passion for cars helps him to drive the success of his organization.
He continue to emphasize: “I do not do this alone, I have a team”. He has build a team to realise his dream! That was my key take away!

Thank you for inviting me to join the CEO Tea Talk🙏🏻

Training Within Industry (TWI), is an important way of building the TPS culture within an organization.

Toyota Motor Corporation is consider one of the company pioneered lean production and which remains one of the best in the world at implementing it.
~ Alan G. Robinson ~

Malaysia’s Micro, Small and Medium Enterprise has recorded a very positive growth for the year 2023 based on the date collected by the Department of Statistic Malaysia, presented by
YB Datuk Ewon Benedick
Menteri Pembangunan Usahawan dan Koperasi!

Great work to all the SMEs (PMKS) owners in Malaysia!

https://www.bernama.com/bm/ekonomi/news_bajet.php/news.php?id=2323941

A mid-year review and strategy session for the next half-year at Obeya!

Visualization is the key to keeping everything that is important to the organization in check. As the saying goes: “Out of sight, out of mind.”

Obeya is an approach used to ensure all key executives are aligned and driving the planned results following the Hoshin Kanri way.

The end of FY 2023/24
VA Team are gathered for Business Planning & Alignment (BPA) for next FY 2024/25.

Not forgetting to also celebrate our small wins along the way!
Thank you each and everyone in the team for the journey we have decided to embark on together!

Completed a 1-Day session on Standardized Work Training!

Customer feedback: We now have a method to communicate both with Top Management and Operation regarding the amount of resources needed for a Work Order.

Standardized Work can help to ensure QCD - Quality, Cost and Delivery (Quantity).

“Make Thing Simple”
To make things simple is never easy to do. However, as long as the task is not yet simple to do, then there is always room for kaizen.

The fastest way to make things simple is by involving all hands to make contribution towards idea for kaizen and try it out. TPS spirit is “learn by doing”.

👏👏👏 Congratulations Pat & Jane for the successful celebration and Happy Birthday 10th Anniversary Chung Chamber! 🥳🎊🎉🎂🥂🎁💐!

Wishing Chung Chamber the continuous success in years to come! 💪💪💪

Obeya : Strategic War Room

Applying the concept of Obeya, we have completed a 2-Days Kaizen PDCAF Workshop improving the layout of a process to reduce the lead-time and achieve better productivity.

The Obeya has help the team to look at the opportunities by all hands and process the issue followed by idea generation.

A great approach to keep focus. As the saying goes “Out of Sight, Out of Mind”. Obeya keep everything we need to focus, and can pick up where we left the topic last.

Wishing friends of near and far a joyous and vibrant Dragon Boat Festival! Enjoy the delicious dumpling, and cherished moments with family and friends. Here’s to celebrating tradition, unity, and good fortune.

Conducted a session of Understanding Lean TPS fundamental class by airplane with one of our showcase plant Mega Label. The focus audience this time are the team leaders and operators. Engaging with the ex*****on level allowing them to participate and feedback.

They are so amazing with the feedback given to the management linking the key learning points with their actual working environment.

Had so much fun conducting a 2-Days Kaizen PDCAF Workshop with this bunch.

We had a Genba session and apply the TPS fundamental knowledge from both the Airplane Game and Lego Game activity. I was surprised by what the observation shared by the team.

The different level of machine height is causing so much inefficiency and hard work to the operators.
We had a great time generating ideas and trial and error to improve the condition.

The lot size was also reduce and some processes was joint together. As a result, we got smaller lot size and faster flow.

Completed a 2-Days Kaizen PDCAF Workshop with client trying to create smaller lot size for faster flow.

The concept of Net Conversion Time Ratio was used to explained the effect of Large lot size vs. Small lot size.
I was impressed by one of the participant on how fast he grasp the concept and wanted to reduce the current lot size to 1/6, making it hourly to replenish.

However, applying the fundamental is still important. Hence, the team apply the knowledge of Standardized Work to complete the new layout chart. I can’t wait to see the actual implementation soon.

よい品よい考 Yoi shina yoi kō - Good Thinking, Good Product

All employee of Toyota are continuously being reminded of this spirit and love by it. This is how Toyota sustain their corporate culture and core values!

Completed a half-day Lean TPS Awareness training using the Airplane Game to help the operations team of the supervisor and team-leader level to understand the idea of Continuous Flow and Small Lot Size!

Now the team can understand the purpose of why Kaizen is important to help organization to achieve financial sustainability.

Completed a 2 Days Kaizen PDCAF Workshop.
We learned that Organization Structure has to support the information flow and escalation process when support from the top is needed.

Key points, it is important to always discuss and made it clear who is the supplier of information and who is the customer of information (5W1H use the information), the more simple, the better.

Did a Kaizen PDCAF Workshop with client reviewing the new layout for higher productivity and lead-time reduction by reducing employee “hard work”.

Visualisation is an important technique for all managers to align the team on the same page and speed up ex*****on!





partners

It was an honour to meet Mr. Chen, the Founder and Executive Chairman of Claytan.
A very wise 92 years old who are still very active and insist on the tradition and culture of having lunches and celebration together with all the team and employees.
Believing in equality for everyone in the organization while we play different roles and responsibility contributing to the growth and development!





partners

Thank you everyone who are working hard contributing to the nation development!
Wishing you all a wonderful day of rest! You deserve it!
Otsukarasamadesuta!





partners

Just completed a 2-Days Genba coaching to improve productivity and lead-time reduction.
There was so much fun observing, analysing the process and idea-generation session to Kaizen. The team also do an instant implementation to verify the result with the operator.

A total joy working with these bunch! ❤️





partners

The origin (Principles) of Toyota Production System is the key to the success in implementation.
Many organization heard of the success of TPS but failed to implement it in their own environment (organization culture).
It was said that about 15% of organization in Japan that tried TPS and out of that only 15% are successful in implementing!
Founder’s philosophy is the foundation of the management system within an organization. Corporate Strategies are important in setting the guiding principles for everyone within the organization in leading team and making decision.

Do you know about the story behind why Japanese Curry Rice are served at Toyota Automobile Museum?

Japanese Curry Rice is a simple dish that can be prepared by many hands. The process allow new employee and seniors team to develop relationship and bonding that will helps in strengthening the communication between the juniors and seniors!





partners

Kinbukuro (Raccoon) is a mascot of Omi Merchant in the Omi Hachiman of Shiga Prefecture.

Kinbukuro have all the characteristics of Omi Merchant’s values. Always remember the account of business while networking (sake time) to growth the business and expanding information network.

🌙Selamat Hari Raya from us to all our Muslim’s Friend!

🕌 Wishing you and your family a joyous celebration! May this festive season strengthen the family bonding with all your loved ones! ❤️

Wishing all our followers and friends a prosperous new year! May abundance of health and wealth be with you always!!

Happy Thaipusam and Happy Holiday Peeps!
Wishing everyone a blessed and safe celebration!!

Wishing you Happy Thaipusam and Happy Holiday! May you all be blessed with good health and fulfilling life.

Stay Safe and Stay Healthy